Process Safety

MANAGEMENT
Facilitator Guide

Solving
the
Puzzle
What’s Inside
Facilitator’s Guidelines
a Overview
b Getting Started
d Presentation Guidelines
f Lesson Plan
h Frequently Asked Questions

1 Introduction
Follow the 14 elements of Process Safety Management to prevent
incidents.

2 Employee Participation
Your commitment to Process Safety Management is important.

3 Process Safety Information

Know the three types of process safety information.

4 Process Hazard Analysis

The four steps to proactively prevent incidents.

5 Management of Change
Written procedures are required when a change occurs.

7 Pre-Startup Safety Review

Steps to ensure safe operation of the process for new and
modified facilities

8 Operating Procedures
Written operating procedures describe duties to be performed
and operating conditions for each part of the process.
 9 Hot Work Permits
Required for any hot work job on or near covered processes.

10 Employee Training
Who needs to be trained and how often?

11 Incident Investigation
The objective and duties of an incident investigation team.

13 Mechanical Integrity
Know the components of a mechanical integrity program.

14 Emergency Planning & Response

Know what to do to prepare for an incident.

15 Contractor Safety
The contractor’s responsibilities for process safety.

16 Audits
What is an audit and when it is conducted.

17 Trade Secrets
When confidentiality is required.

18 Process Safety Management Quiz

Review what you learned.

© 2003 Summit Training Source® Inc. All rights reserved. No part of this book may be reproduced
in any form or by any means without written permission from Summit Training Source® Inc.
If you wish to purchase additional copies please call our office at 1-800-842-0466.
 Overview
The following sections provide detailed information, discussion
topics and review questions for each of the 14 elements of Process
Safety Management, or PSM. The roles, job functions and respon-
sibilities of the group being trained will determine the depth and
scope of information covered for each element.

The objective of PSM is to prevent catastrophic incidents caused by

the uncontrolled release of highly hazardous chemicals. Process
Safety Management can accomplish this goal through a systematic
approach that includes identifying, analyzing and controlling the
chemicals in the process.

To be effective, Process Safety Management requires the

participation of all personnel at your facility. This includes the plant
manager, supervisors, engineers, operators, mechanics and even
contractors. Each person needs to contribute his or her specific
expertise, whether it is experience, technology or process
knowledge.

a © Summit Training Source, Inc.

 Getting Started
Training Materials
Collect all of the necessary materials and supplies before train-
ing begins. Here are some suggested materials and supplies:

• A training location that is free of distractions, has good

lighting, and a comfortable temperature.

• Desks and chairs arranged so that everyone will be able to

see the viewing screen, the facilitator, and each other.

• The video, a VCR, and a TV with a remote. Make sure the

video is rewound.

• An employee handbook and pen/pencil for each trainee.

Each handbook includes a quiz at the back, which can be
used to test comprehension and document training.

• Other supplies and equipment you may need are:

blackboard chalk, paper, handouts, transparencies,
overhead projector, markers, notepads, etc.

• Additional information, such as a copy of the regulation or

other reference tools.

© Summit Training Source, Inc. b

 Getting Started continued
Preparation
A successful presentation requires preparation and planning.
Give yourself several days before the training session to get
organized.

• Locate and schedule the training site as soon as possible.

• Notify trainees of the training date and time, the training

schedule, and proper dress.

• Obtain all necessary equipment and supplies.

• Make sure you know how to operate the TV, VCR, and other
equipment. Check to ensure that it is working properly.
Replace or repair any damaged equipment.

• Review all training materials, including the Facilitator’s

Guide, handouts, and any other reference materials.

• Prepare your presentation, including a lesson plan or

outline of the training. Include the training goals and
objectives. Some presentation guidelines are included on
the next page. A sample lesson plan has been included on
page f of this Facilitator’s Guide.

• A day or so before conducting the training session, you may

want to have participants take the quiz as a pre-test. The
results of this test can help you to determine weak areas to
focus on during the training session.

• Preview the videotape. Note any key points you want to

expand upon in your training.

c © Summit Training Source, Inc.

 Presentation Guidelines
How you present the training course can have a great
impact on learning. By following these simple presentation
guidelines and keeping your objectives in mind, you can
effectively and efficiently get the most out of your training
session.

Organize Training Time Efficiently

In today’s busy work climate it can be difficult to find the time
needed for training, so it is important to be organized and
well-prepared when you do schedule training sessions.
Whether you use Summit’s suggested lesson plan or not, it is
important to have a lesson plan prepared that you can imple-
ment comfortably. This ensures that time spent in training is
productive and beneficial for everyone.

Stress the Purpose and Goals of Training

Training needs to be goal-oriented. State the purpose of
training in a clear, specific manner - whether it’s to reduce
injuries, increase production, improve quality, improve work-
ing conditions, etc. Review the goals and objectives of the
training so trainees know what is expected of them.

Capture Their Attention

Training needs to be interesting and compelling to hold
trainees’ attention. To help motivate learners, give them spe-
cific evidence that their effort makes a difference and provide
feedback on their progress. Also, remember that the first
experience with a new subject usually forms a lasting impres-
sion on the learner. By making that experience a positive
one, you can help ensure your audience retains the informa-
tion learned.

© Summit Training Source, Inc. d

 Presentation Guidelines continued
Make New Learning Experiences Pleasant
For some adults, past experiences with education were
unpleasant and not helpful. Adults learn best when they feel
comfortable. By making the learning environment open and
friendly, you can help adults to feel secure in their new learn-
ing experience. Offer support and feedback as often as possi-
ble, and be ready to provide extra attention to those who may
require it.

Ask If There Are Any Questions

When most adults learn new information that conflicts with
what they already know, they are less likely to integrate those
new ideas. It is very important to make sure participants fully
understand the training and do not have any unresolved ques-
tions. Provide for a question and answer period so partici-
pants can resolve those questions and/or answer questions
throughout the training session.

e © Summit Training Source, Inc.

 Lesson Plan
As a qualified trainer, your job is to effectively communicate
a great deal of information in a well-organized manner. By
preparing a lesson plan, you can ensure that each minute of
the training session is productive. Summit has provided a
suggested lesson plan for your use.

1. Program Objective
This guide reviews Process Safety Management. In it, we
will cover:
• Employee Participation
• Process Safety Information
• Process Hazard Analysis
• Management of Change
• Pre-Startup Safety Review
• Operating Procedures
• Hot Work Permits
• Employee Training
• Incident Investigation
• Mechanical Integrity
• Emergency Planning &
Response
• Contractor Safety
• Audits
• Trade Secrets

2. Show the Video: “Process Safety Management”

3. Discussion and Demonstration

To help relate the training to your site, you may wish to incor-
porate your own discussion topics and exercises. Key issues
you might consider include:
• Discuss your facility’s procedures for conducting the various
elements of Process Safety Management
• Employee training required
• Safe work procedures

© Summit Training Source, Inc. f

 Lesson Plan continued
4. Use Handbooks to Reinforce Training
The handbooks increase comprehension and reinforce the
information learned in the video program by explaining the
main points and expanding on the original material. For
increased employee information retention, go over one sec-
tion at a time and stop to answer questions. The quiz at the
back of the Facilitator’s Guide is provided to document
employee training. Answers to the quiz are in bold.

5. Questions and Answers

Provide for a Q&A session to answer any questions. It may
be necessary to review some of the material when providing
answers. The employee handbook, equipment manuals, and
other reference tools may be helpful.

g © Summit Training Source, Inc.

 Frequently Asked Questions
Is there a procedure that must be followed when there is a change
in the process?

All changes, including those that are temporary, are required to be

documented. These written procedures must include authorization
requirements for the proposed change, the technical basis for the
change, health and safety considerations, changes required for oper-
ation and maintenance procedures and the time period for the
change. A Pre-Startup Safety Review must be performed if the
change is significant enough to require a modification in the Process
Safety Information. This should be done after the change and
before hazardous chemicals are introduced into the process.

What is an Incident Investigation Team and what is its purpose?

The job of the Incident Investigation team is to investigate incidents

that resulted or could have resulted in a catastrophic incident.
Members of this team include personnel who must be proficient in
investigative, fact finding and reporting skills and the process
involved. At the end of the investigation, they must compile a report
containing the description of the incident and the date it occurred,
the date the investigation began, a description of the investigation
and findings of the factors that contributed to the incident.

© Summit Training Source, Inc. h

 Introduction
Processes that use highly hazardous chemicals could cause danger
to you and damage to the facility and the surrounding community
if an explosion, spill or fire happened in the work place.

This has been demonstrated with recent explosions that have been
highlighted in the news in the past few years.

Objective

The objective of Process Safety
Management, or PSM, is to pre-
vent any incidents which could
lead to property damage, major
injuries or even death. This
overview of PSM will help you
see how your job fits together
with the other elements of PSM.
By following procedures for
PSM and respecting the poten-
tial hazards, you can prevent
incidents in your facility.

There are 14 elements in Process Safety Management:

• Employee Participation • Employee Training

• Process Safety
Information
• Process Hazard Analysis
• Management of Change
• Pre-Startup Safety
Review
• Operating Procedures
• Hot Work Permits
• Incident Investigation
• Mechanical Integrity
• Emergency Planning &
Response
• Contractor Safety
• Audits
• Trade Secrets

1 © Summit Training Source, Inc.

 Employee Participation
A written plan of action is needed which details employee
participation in the process.

Your participation in the differ- edge, work experience, training

ent elements of PSM is impor- or education, your participation
tant. Whether it is your knowl- is a valuable part of its success.

© Summit Training Source, Inc. 2

 Process Safety Information
Written Process Safety Information is needed.

There are three kinds of Process Safety Information:

• Information on the process chemicals
• Information on the process technology
• Information on the process equipment

Process Chemical inventory of chemicals used,

Information
Process Chemical Information
includes toxicity, permissible
exposure limits (PELs), physical
data, reactivity, corrosion and
erosion effects, thermal and
chemical stability and the
potential effects of accidental
mixing of different chemicals.
Process Technology
Information
This information includes a
block flow diagram or simpli-
fied process flow diagram
showing the flow of the mater-
ial and process chemistry.
Process Technology Information
also includes an evaluation of
the results of a change, the
and safe upper and lower limits
for variables such as tempera-
ture, pressures, flow and com-
position.
Process Equipment
Information
Process Equipment Information
includes the materials of con-
struction, piping instrument dia-
grams, electrical classification,
design codes and standards
used, safety systems, and relief
and ventilation system designs.
Newer processes will also
include material and energy
balances. Documentation will
verify equipment follows gener-
ally accepted good engineering
practices.

3 © Summit Training Source, Inc.

 Process Hazard Analysis
An investigation team will perform an initial Process Hazard
Analysis.

Process Hazard Analysis (PHA) is 3. Develop prevention

a way of thinking of all the pos-
sible things that could go
wrong in the process that
would result in a catastrophic
incident. If you conduct a PHA,
there are four main steps you
need to follow:
1. Identify possible problems
in the process
2. Identify possible causes
and results
techniques
4. Evaluate the current
system and operations
Process Hazard Analysis is
conducted by plant personnel
who are knowledgeable in
engineering, the process being
analyzed and/or the methodol-
ogy being used.

© Summit Training Source, Inc. 4

 Management of Change
Written procedures are needed to manage changes to process
chemicals, technology, equipment, procedures, and also to facilities
that affect a covered process. Even temporary changes are subject
to management of change.

Changes in process technology include changes in the flow route.

Changes may also happen in production rates, operating conditions
to improve yield and quality, and to equipment.

"Replacement in kind" is not same design, it would not be

considered change. For exam- considered a change in the
ple, if you replace a valve in the process.
process with one that has the

5 © Summit Training Source, Inc.

 Written procedures should
accompany all changes. This
should include:

• Time period for the

change KEY POINT
• Technical basis for the
Follow-up to see if the
change
change requires any
• Health and safety consid-
changes to the process
erations
safety information
• Authorization for the
and/or process hazard
proposed change analysis.
• Changes required for
operation and maintenance
procedures

Follow-up should be performed

to see if the change requires
any changes to the process safe-
ty information and/or process
hazard
analysis.

© Summit Training Source, Inc. 6

 Pre-Startup Safety Review
A pre-startup safety review needs to be performed for new and
modified facilities when the modification requires a change in the
process safety information.

A pre-startup safety review is a • Safety, operating,

final check to make sure all
steps have been taken to ensure
safe operation of the process.
Before hazardous chemicals are
put into the process, the pre-
startup safety review will make
sure that the following have
been done:
maintenance and
emergency procedure
meet all requirements
and are in place.
• Training of each employee
involved in operating a
process has been complet-
ed.

• All construction and

equipment meet design
requirements.

• For new facilities, a

process hazard analysis
has been performed and
any recommendations
have been resolved or
carried out before start-
up.

7 © Summit Training Source, Inc.

 Operating Procedures
Written operating procedures are needed to provide clear
instructions for safely conducting all activities in the
process.

The operating procedures process, results of deviation and

describe in detail the duties to
be performed and operating
conditions kept for each part of
the process.
This includes steps for startup,
operating procedures for nor-
mal, temporary and emergency
situations, and emergency and
normal shutdown procedures.
The procedures spell out oper-
ating limits for each part of the
how they can be avoided and
corrected if they do happen.
Operating procedures also
include health and safety provi-
sions, data that needs to be
recorded, the built-in safety sys-
tems in the process, safe work
practices for procedures that
affect the process such a lock-
out and tagout, and what con-
stitutes upset conditions.

© Summit Training Source, Inc. 8

 Hot Work Permits
A hot work permit is required for hot work jobs carried out
on or near a covered process.

Hot work includes any spark- • Dates the work is

producing activities, devices and
open flames such as welding,
soldering or grinding. The per-
mit provides the following
information:
• Identity of the object
that the hot work is
being done on.
authorized for.
• Fire prevention and
protection requirements.
All affected personnel, such as
operators, should be notified of
the hot work. The permit must
be kept on file until the hot
work is done.

9 © Summit Training Source, Inc.

 Employee Training
Employees involved in the process will be trained on an
overview of the process and their specific job function as
it relates to the process.

Refresher training and documentation is necessary at least

every three years.

If you are involved with the ards of the chemicals and the
process, directly or indirectly, it process. This includes operators,
is important that you under- maintenance and support per-
stand the safety and health haz- sonnel, and outside contractors.

© Summit Training Source, Inc. 10

 Incident Investigation
Any incident or near miss that ended in or could have result-
ed in a dangerous release of a highly hazardous chemical in
the work place should be investigated within
48 hours of the event.

Objective If the incident involved a con-

The objective of the incident
investigation is to find possible
causes of all incidents or “near
misses” and solutions to prevent
them from happening again.
The Investigation Team
The investigation team should
be skilled in investigating, fact
finding and reporting skills, and
the process involved.
tract employee, then the team
must have a contractor repre-
sentative.
The team’s job is to analyze all
possible causes of the incident,
gather a list of the sequence of
events, and determine the cause
of incident.

11 © Summit Training Source, Inc.

 Finally, the investigation team
puts together a report that is
shared with all personnel
involved in or affected by the
incident.

The report must have the

following information:

• A description of the
incident and the date it
KEY POINT
happened
The team’s findings
• The date the investiga- and recommendations
tion began are detailed in a writ-
ten report.
• A step-by-step descrip-
tion of the investigation

• The investigation team's

findings of the factors
that led to the incident

• Recommendations to
eliminate chances of a
similar incident occurring
in the future.

© Summit Training Source, Inc. 12

 Mechanical Integrity
The Mechanical Integrity of process equipment must be maintained.
Maintaining mechanical integri-
ty means making sure that
process equipment operates the
way it is designed to without
any problems. A mechanical
integrity program includes the
following:
13
• Develop and use written
maintenance procedures
• Train maintenance
personnel
• Set up and document
testing and inspection
procedures
• Correct equipment
defects
• Assure quality of new
equipment, materials
and parts
A quality assurance system is
also a part of the PSM program
because it helps to keep the
integrity of the process by
making sure proper materials
are used and the right codes,
standards and procedures are
followed.
© Summit Training Source, Inc.
 Emergency Planning & Response
An Emergency Action Plan for the whole plant should include pro-
cedures for handling small releases.

An Emergency Action Plan Additional training for cleanup

should include arrangements
for warning and clearing all
personnel from the facility if a
major accidental release of
highly hazardous chemicals
happens.
teams will be provided. This
should include safe work prac-
tices and steps for cleanup and
disposal of hazardous chemi-
cals.

Plans and procedures are also

needed for the handling of
small spills.

© Summit Training Source, Inc. 14

 Contractor Safety
The safety record of a contractor should be checked. The contractor
will need to train his employees on the safe work practices and safe-
ty rules of the facility, the potential hazards involved, and the
Emergency Action Plan.

The safety record and training
program of a contractor must
be verified BEFORE the job is
awarded. This includes any
maintenance, repairs, turn-
around jobs, major renovations
or specialty work.
BEFORE the contractor begins
work in the process area, all
contract employees should be
told about the possible hazards,
safe work practices, and the
Emergency Action Plan.
The contractor must train his or
her employees on safe work
practices and document that
training was given and under-
stood. The contractor is respon-
sible for making sure his or her
employees follow all safety rules
and for telling the facility about
any safety hazards that the con-
tract work might cause or that
his employees identify.

15 © Summit Training Source, Inc.

 Audits
To make sure that evaluations of the Process Safety Management
system are carried out and proper procedures are being followed,
an audit will be completed at least every three years.

An audit is a way of checking to

make sure that all elements of
PSM are being followed and
meeting their goals.

It is done by at least one

person who is knowledge-
able in the process.

The audit is usually done with a

checklist and includes a review
of logs, records and visual
observations and inspections.

The most important part of the

audit is a follow-up on all rec-
ommended actions to improve
PSM at your facility.

© Summit Training Source, Inc. 16

 Trade Secrets
Your employer will make available to proper personnel any infor-
mation needed to comply with the standard.

All information needed for to the proper personnel.

gathering process safety infor-
mation, developing process
hazard analysis and operating
procedures, conducting inci-
dent investigations, emergency
response and planning, and
audits should be made available
If this information is made
available to you, you may be
required to enter a confidential-
ity agreement if it involves trade
secrets.

17 © Summit Training Source, Inc.

 Test Yourself With This Process
Safety Management Quiz
Your Name Date

______________________________________________________

1. Process safety information includes information on which

of the following?
A. Audits B. Employee training
C. Process technology D. None of the above

2. The four main steps in process hazard analysis are

identifying potential problems, identifying probable
causes and consequences, prevention techniques and
evaluation of current system and operations.
A. True B. False

3. A methodology used to conduct a process hazard analysis

is:
A. Family tree diagram B. What-if/checklist
C. Fault tree analysis D. Both B and C

4. Management of change occurs when there are changes

in process chemicals, technology, equipment, procedures
or facilities.
A. True B. False

5. Which of the following information should be

documented when a change in the process takes place?
A. Technical basis for B. Changes required for
the change operation & maintenance
procedures
C. Health & safety D. All of the above
considerations

6. A pre-startup safety review should be performed after

hazardous chemicals have been introduced into the
process.
A. True B. False

© Summit Training Source, Inc. 18

 7. What operating guidelines do the operating procedures
spell out?
A. Temperature ranges B. Hazard limits
C. Flow rates D. Both A and C

8. Hot work permits do not always need to identify the

object on which the hot work is being performed.
A. True B. False

9. Refresher training for employees must be provided how

often?
A. Every year B. At least every three
years
C. Once a month D. Never

10. Incident investigations should begin within 48 hours of

the incident.
A. True B. False

11. Maintaining mechanical integrity means that equipment

is kept in good operating conditions and proper
procedures are followed.
A. True B. False

12. The standard requires employers to establish and

implement written operating procedures that must
address steps for each operating phase.
A. True B. False

13. The contractor does not have to train employees on:

A. Rescue procedures B. Safe work practices
C. Potential hazards D. Provisions of the emer-
gency action plan

14. The employer must conduct evaluations of the process

safety management system at least every three years.
A. True B. False

15. The employer must make available to the proper

personnel all necessary information to comply with the
standard without regard to possible trade secret status
of the information.
A. True B. False

19 © Summit Training Source, Inc.

 Notes

© Summit Training Source, Inc. 20

 Quiz Answers
1. C Process technology
2. A True
3. D Both B and C
4. A True
5. D All of the above
6. B False
7. D Both A and C
8. B False
9. B At least every three years
10. A True
11. A True
12. A True
13. A Rescue procedures
14. A True
15. A True

21 © Summit Training Source, Inc.

 Notes

© Summit Training Source, Inc. 22

 Notes

23 © Summit Training Source, Inc.

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